Overview
Hydrogen can play a key role in the decarbonisation of Australian heavy industry, provided that it is utilised in a de-risked, sensible and cost-effective way. However, there is considerable uncertainty around supply (particularly cost and availability) and the impact of integrating hydrogen into current systems on materials, system performance and product quality.
Recent literature and industrial engagement make clear a need for greater understanding of materials compatibility with hydrogen, especially for especially metals and alloys.
The interaction of hydrogen with materials is related to specific operating conditions. To be able to predict the influence of changes in temperature, pressure and hydrogen concentration on industrial processes, a classification system based on reliable test procedures is needed.
This project will consider aspects of materials compatibility relevant to hydrogen integration with infrastructure and materials relevant to all HILT CRC industries and address significant gaps in the ability to reliably test and assess materials for specific applications.
Project Details
RP2.015 focuses on addressing technology gaps in materials science to support the safe and effective use of hydrogen in industrial processes.
The project aims to aid industry decision-making by identifying and mitigating risks related to hydrogen embrittlement and its impact on the structural integrity of metals used in iron ore processing, alumina production and cement manufacturing.
By developing the fundamental and practical understanding needed to make informed decisions on fuel switching at scale in high-temperature industrial processes, this project will:
- help industry formulate investment strategies and de-risk technology demonstrations
- provide information to guide the design of new technologies.
The project work program includes:
- Investigating the impacts of hydrogen on structural materials, under industrially relevant conditions of temperature, pressure and gas composition.
- Comparing recognised laboratory-scale testing methods to evaluate hydrogen impact on materials with development of a recommended laboratory testing approach to be used in further work.
- Conducting testing using the recommended method from step 2 on representative alloy groups (low-alloy steels, stainless steels, Inconel and NiCr steels and nickel alloys). Testing will also examine welds of select materials.
HILT CRC Milestones
- 2.4 Blending of alternative low-carbon fuels for current industrial processes
Research Areas
- New technology to accommodate multiple energy sources and offer flexibility in switching between them
- New technologies for high-temperature heat
- Assessment of challenges for hydrogen as an alternative fuel in existing processes
- Blending of alternative low-carbon fuels for current high-temperature processes
- High-temperature heat in existing processes
- Biomass, waste and other low carbon fuels, including new combustion technologies
Outcomes
Planned outcomes
- An improved understanding of the impact of staged replacement of natural gas with hydrogen on materials in high-temperature processes, with a focus on materials compatibility and process performance.
- Insights into the techno-economics of different fuel-switching strategies, with particular consideration given to retrofitting versus new build, that can support industrial demonstration and ongoing research, development and demonstration activities.
- A knowledge database with fully evaluated testing methods for hydrogen embrittlement of a variety of materials under typical industrial process operating conditions.
- Knowledge on possible solutions and mitigation strategies of materials risk in hydrogen environments.
- Providing advice regarding the deployment of the materials, detailing expected performance under specific operating conditions, expected lifetime and damage, and costs of various options.
- Techno-economic and life cycle analysis of various scenarios comparing retrofitted materials and new designs.
Results to date
In its first phase, RP2.015 identified two main technological gaps:
- The need for a reliable methodology to introduce hydrogen into materials enabling testing of the hydrogen permeation effect.
- Consistent and repeatable mechanical testing methods to quantify hydrogen’s impact on materials, particularly under varying conditions such as elevated temperature, high pressures, hydrogen concentrations, impurities and environmental factors.
Published Scientific Papers
- Ilyushechkin A, Gray V, Ingle R, Carter L, Schoeman L. Forensic Investigation of Stainless Steel 316 Hydrogen-Membrane and Ammonia-Cracking Reactors Through Mechanical Testing. Corrosion and Materials Degradation. 2025; 6(2):17.